Processes Description Resistance Spot Welder Resistance Spot Welding 003 335A July 2005 Visit our website at www.MillerWelds.com HANDBOOK FOR Resistance Spot Welding WARNING This document contains general information about the topics discussed herein. This document is not an application manual and does not contain a complete statement of all factors pertaining to those topics. This installation, operation, and maintenance of arc welding equipment and the employment of procedures described in this document should be conducted only by qualified persons in accordance with applicable codes, safe practices, and manufacturer’s instructions. Always be certain that work areas are clean and safe and that proper ventilation is used. Misuse of equipment, and failure to observe applicable codes and safe practices, can result in serious personal injury and property damage. ARC WELDING can be hazardous. [...]... charts are intended as guides for setting up resistance spot welding procedures The exact time, pressure, and current setting will depend on the specific application and the KVA rating of the resistance spot welding machine employed Some areas of the tables may not apply to resistance spot welders in the KVA ratings available from this company Table 4-1 Resistance Spot Welding Machine Specifications... designed for wear resistance and compressive strength at high temperatures Group B, Class 10 alloys have about 40 percent the conductivity of copper with conductivity decreasing as the number value increases Group B electrode tips are not normally used for applications in which resistance spot welding machines would be employed UG-003 335 Page 7 4-6 Practical Uses Of Resistance Spot Welding Y SPOT WELDING. .. on hot-rolled steels will act as an insulator and prevent good quality resistance spot welding Surfaces to be joined by this process should be clean, free of oxides, chemical compounds, and have a smooth surface 4-12 Materials Data For Resistance Spot Welding This section of the text will consider methods used for resistance spot welding some of the common metals that are used in fabrication work It... base metal within the throat of the unit for any one resistance spot weld and almost none of the base metal in the throat for the second spot weld The current at the weld joint will be less for the first weld The reason is the reactance caused by the ferrous material within the arc welding circuit Resistance spot welding machines are applicable to low carbon steel welding They must be used within their... lower pressures require less amperage from the resistance spot welding machine This fact should be carefully noted particularly when using a heat control with the various resistance spot welding machines 4-5 Electrode Tips Copper is the base metal normally used for resistance spot welding tongs and tips The purpose of the electrode tips is to conduct the welding current to the workpiece, to be the focal... will be much lower for “stack” resistance spot welding, which explains why such welding practices are avoided whenever possible Disregarding the quality factor, it becomes apparent that the number of thicknesses of a material which may be successfully resistance spot welded at one time will depend on the material type and thickness as well as the KVA capacity of the resistance spot welding machine KVA... single impulse resistance spot welding applications Current is very often economically impractical to control It is also unpredictable in many cases Most resistance spot welds are made in very short time periods Since alternating current is normally used for the welding process, procedures may be based on a 60 cycle time (sixty cycles = 1 second) Figure 4-2 shows the resistance spot welding time cycle... Factor Resistance spot welding depends on the resistance of the base metal and the amount of current flowing to produce the heat necessary to make the spot weld Another important factor is time In most cases several thousands of amperes are used in making the spot weld Such amperage values, flowing through a relatively high resistance, will create a lot of heat in a short time To make good resistance spot. .. the equipment T1 P TONGS S ELECTRODE TIPS Resistance spot welding techniques do not require extensive or elaborate safety precautions There are some common sense actions that can, however, prevent injury to the operator TONGS Figure 4-3 Resistance Spot Weld Heat Zones Anytime work is being done in a shop, it is a wise rule to wear safety glasses Resistance spot welding is no exception to the rule! Very... Steels The chrome-nickel steel alloys (austenitic) have very high electrical resistance and are readily joined by resistance spot welding The consideration of great importance with these materials is rapid cooling through the critical range, 800° to 1400° F The rapid quench associated with resistance spot welding is ideal for reducing the possibility of chromium carbide precipitation at the grain boundaries . Processes Description Resistance Spot Welder Resistance Spot Welding 003 335A July 2005 Visit our website at www.MillerWelds.com HANDBOOK FOR Resistance Spot Welding WARNING This document contains general information. illustrated. For clarity, the various parts of the resistance spot welding machine are identified. UG-003 335 Page 6 SECTION 4 − FUNDAMENTALS OF RESISTANCE SPOT WELDING 4-1. Principle Resistance welding. shows a resistance spot weld nugget compared to a gas tungsten-arc (TIG) spot weld. RESISTANCE SPOT TUNGSTEN ARC SPOT Figure 4-1. Resistance And TIG Spot Weld Comparison The gas tungsten-arc spot